Lubrication unit management system

ABSTRACT

A system for remotely controlling and documenting valve lubrication. The system includes an operator unit programmed to communicate with a remote controller unit that actuates the transfer of lubricant to user-selected valves.

CITATION TO PRIOR APPLICATIONS

The present application is a Continuation of U.S. Non-Provisionalapplication Ser. No. 16/521,469, titled “LUBRICATION UNIT MANAGEMENTSYSTEM” and filed Jul. 24, 2019, which claims priority to U.S.Provisional Application No. 62/702,763, titled “LUBRICATION UNITMANAGEMENT SYSTEM” and filed Jul. 24, 2018.

FIELD OF THE INVENTION

The present invention relates generally to systems for the remotelubrication of valves.

BACKGROUND OF THE INVENTION

Traditional methods for valve lubrication involve manual control oflubricant flow to valves. This manual approach; however, can oftenresult in improper lubrication that leads to valve/bearing failurerequiring increased expenditures for maintenance and valve replacement.Prior art approaches to valve lubrication also typically result ininsufficient, real-time lubrication documentation.

In addition to these concerns, prior art methods also involve highlevels of energy consumption, lubricant consumption, equipment downtime,operating expenses, and waste relative to the automated systems andmethods of the present invention.

Furthermore, prior art methods are hampered by the practicalconsiderations of time and available personnel as these constraintsoften render such methods ineffective at keeping up with the greasingrequirements of larger systems. Accordingly, industrial operations,utilizing these prior art methods, would have to be halted in order toensure proper equipment maintenance.

Additionally, reliance on manual lubrication also puts human operatorsat risk when attempting to access difficult-to-reach points or valvesthat may be located over or under machinery.

BRIEF DESCRIPTION OF THE DRAWINGS

All illustrations of the drawings are for the purpose of describingselected versions of the present invention and are not intended to limitthe scope of the present invention.

FIG. 1 is a perspective view of one embodiment of an operator unit.

FIG. 2 is a top view of one embodiment of an operator unit.

FIG. 3 is a top perspective view of one embodiment of a remotecontroller unit.

FIG. 4 is a top perspective view of a sensor assembly and coupled PLC inone embodiment of a remote controller unit.

FIG. 5 is a sectional view of one embodiment of a remote controllerunit.

FIG. 6 is a top diagrammatic view of one embodiment of an operator unit.

FIG. 7 is a top diagrammatic view of one embodiment of a remotecontroller unit.

FIG. 8 is a diagram of interactions between components in one embodimentof the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The present invention provides an effective solution to the growing needfor adequate and verifiable lubrication and documentation thereof.Through use of, in certain embodiments, a supervisory control and dataacquisition (“SCADA”) system, efficient remote valve lubrication andrecord generation is achieved. Rather than rely on manual production ofrecords that may not accurately reflect actual levels of lubrication,embodiments of the present invention are configured to recordlubrication data tied to connected sensors in real-time during eachlubrication operation.

In reference to FIGS. 1-8 , certain embodiments of the present inventionrelate to a lubrication unit management system that consists of fourprimary components: a remote controller unit 2, an operator unit 1, anair supply unit 3, and a lubricant supply unit 4.

The remote controller unit is self-contained and couples a sensorassembly 5 (utilizing several sensors described below) with aprogrammable logic controller (“PLC”) control panel 6 to allow formeasurement and regulation of both air and lubricant flow through thesystem. Specifically, the sensor assembly includes an air pressuretransmitter, an air-operated pump solenoid valve, a lubricant pressuretransmitter, and a lubricant flow transmitter each of which is coupledto the PLC. The remote controller unit may be contained in a sturdy,movable housing in some embodiments composed of a hard polymer material.The various components of the sensor assembly may be wired to PLCterminal blocks 7 using quick-disconnect type terminals.

The remote controller unit may be configured to be powered by thecharger port inside a vehicle such as car or truck. Additionally, it isdesigned to operate using 12 VDC incoming power, but it can also bepowered from a wall-mounted 120 VAC receptacle though this would requirethe use of a 120 VAC-to-12 VDC power adapter.

The lubricant flow transmitter is a flow rate sensor and coupled to apositive displacement flow meter. The lubricant flow transmitter isconfigured to send an analog signal representative of lubricant flowthrough the sensor assembly to the PLC. The lubricant pressuretransmitter can be any commercially available pressure sensor capable ofcommunicating (typically through an analog signal) with the PLC. Thelubricant pressure transmitter is configured to send an analog signalrepresentative of lubricant pressure in the sensor assembly to the PLC.

Similarly, the air pressure transmitter may be any commerciallyavailable sensor capable of communicating (typically through an analogsignal) with the PLC. The air pressure transmitter is configured to sendan analog signal representative of air pressure in the sensor assemblyto the PLC. The air-operated pump solenoid valve may be any commerciallyavailable solenoid valve that is capable of actuation by the PLC viaelectrical current output −24 VDC in certain embodiments.

In certain embodiments, the air supply unit is coupled to the remotecontroller unit via an air supply input connector 8 that feeds into thesolenoid valve. When actuated, the solenoid valve allows air to flowthrough the system via a hose or tube that is coupled to the airpressure transmitter and ultimately terminates in an air supply outputconnector 9. The PLC may activate/deactivate the solenoid valve based onair pressure measurements received from the air pressure transmitter.The air supply output connector is coupled to the lubricant supply unitto allow for airflow to the lubricant supply unit when the solenoidvalve is actuated thereby causing lubricant to flow toward the remotecontroller unit.

The lubricant supply is further coupled to remote controller unit via alubricant supply input connector 10 that feeds into the positivedisplacement flow meter. As lubricant is pumped from the lubricantsupply unit into the lubricant supply input connector and into thepositive displacement flow meter, the flow is measured by lubricant flowtransmitter. Lubricant continues to flow through the positivedisplacement flow meter into a hose or tube coupled to lubricantpressure transmitter and ultimately through a lubricant supply outputconnector 11. The PLC may activate/deactivate the solenoid valve basedon lubricant pressure measurements received from the lubricant pressuretransmitter or on lubricant flow measurements received from thelubricant flow transmitter. As lubricant flows, the PLC keeps track oftotal volume (derived from flow rate and flow time) to ensure the targetquantity of lubrication is achievd. The lubricant supply outputconnector is ultimately coupled to the relevant valve(s) 12 and allowslubricant to be pumped to said valve(s).

In certain embodiments, air pressure transmitter cables 13, lubricantpressure transmitter cables 14, and lubricant flow transmitter cables 15provide wired communication with the PLC. The lubricant flow transmittertransmits its analog signal to the PLC in pulses for high-speedcounting.

PLC-control of the solenoid valve is achieved through communicationbetween the remote controller unit and the operator unit. In someembodiments, solenoid valve cables 16 provides wired communication withthe PLC. The operator unit comprises a touchscreen panel computer 17that serves as a human-machine interface (HMI) and is running SCADAsoftware. Communication between the remote controller unit and operatorunit may be achieved through radio signal transmission via radio modems18 in both units. The operator unit is designed to be powered using twodifferent voltage sources −120 VAC and 12 VDC. The 12 VDC power can bedrawn from the charger port inside a vehicle such as a car or truck. The120 VAC power can be derived from a wall-mounted 120 VAC receptacle. A3-position selector switch may be included for power-supply selection.The operator unit may also be configured to include and be powered by arechargeable battery.

The operator unit may be programmed to effectuate remote lubrication ofuser-selected valves that comports with O.E.M. lubrication requirementsand to record data related to such lubrication operations.

The operator unit touchscreen panel computer may include a display 19that is configured to present PLC clock seconds that are constantlyupdated while there is communication between the operator unit andremote controller unit. The display may also be configured to displaynavigation buttons that allow users to move between application screens.

In certain embodiments a lubricant injection button is also displayedand is used to begin a lubrication operation. When this button ispressed and a lubrication operation begun, the user may be prompted toenter operation-specific data (customer name, well name, service ordernumber, etc.). Upon submission of this operation-specific data (or afterstarting the operation in embodiments where no such data is requested),the user will be prompted to enter valve information (part number,serial number, valve manufacturer, etc.). The user will be furtherprompted to select valve type (such as API 6A, 6C, and 6D valves).

As needed for the type of valve selected, a pop-up menu may appearprompting the user to select further valve-specific information (modeltype, size, working pressure, actuation type, etc.). Additionally,certain valve types may also prompt the user to select the position ofthe valve from a valve tree diagram. The selected valve on the treediagram may change color to allow the user to visually identify that thecorrect valve has been selected. In the case that valve positioninformation is requested, the user will be prompted to confirm theposition selection before the operation continues.

When valve type (and position where relevant) have been selected, theuser may press a calculate button that will determine that amount oflubricant to apply. In the event that an incompatible combination ofvalve type and position has been selected, pressing the calculate buttonmay be configured to return instructions to modify the selected datarather than calculate lubricant quantity. If all data entered is validand compatible, a save button may be pressed after the calculation tosave all data to a database. A confirmation message box may display toconfirm successful database entry.

A start injection button may be displayed and pressed to then initiatelubrication of the selected valve. Once pressed, the operator unit willcause the PLC in the remote controller unit to actuate the solenoidvalve to begin lubrication. The display may be configured to presentlive readings of air pressure, lubricant pressure, and lubricantquantity during the lubrication operation. These readings may optionallybe presented on a graph that depicts trends in real-time.

A status indicator may be displayed during the lubrication operation toindicate current operational progress. This indicator may include thefollowing display messages:

-   -   “Running” when the lubrication operation is in progress with the        solenoid valve energized. The readings described above will be        constantly measured by the PLC and fed to the operator unit        while the operation is in this state.    -   “Paused” when the user elects to temporarily halt the operation        or after an active shutdown event has been cleared. A resume        button may be pressed to continue operations that have been        paused.    -   “Shutdown” if certain active shutdown events have occurred. In        the event of a shutdown, the indicator may further display the        specific active shutdown event that triggered the shutdown.    -   “Aborted” when a user elects to permanently halt an operation        prior to completion.    -   “Complete” when the calculated amount of lubricant has been        directed to the selected valve.

As discussed above, a lubrication operation may be halted if an activeshutdown event is encountered. When an active shutdown event halts anoperation, the solenoid valve is de-energized. Such events may include:

-   -   Exceeded lubricant pressure threshold. A lubricant pressure        threshold may be set that will trigger a shutdown if reached.        The operator unit may be programmed to shut down a lubrication        operation in which lubricant pressure is more than 1,000 psi        over the user-selected working pressure.    -   Insufficient air pressure. A required air pressure threshold may        be set that will trigger a shutdown if not maintained. The        operator unit may be programmed to shut down a lubrication        operation in which air pressure falls below 60 psi.        Additionally, an intermediate threshold may be set at 70 psi        that causes a low air pressure indicator to activate when air        pressure falls below said intermediate threshold for more than        five (5) seconds. Unless air pressure falls below the require        air pressure threshold, the operation will not be shut down.    -   Insufficient lubricant flow. A lubricant transfer quantity        threshold may be set that will trigger a shutdown if not        reached. The operator unit may be programmed to shut down a        lubrication operation if the total quantity of lubricant        injected over a one (1) minute duration is less than 0.05        ounces. Low lubricant flow may be indicated on the display        during this event.

After an active shutdown event halts a lubrication operation, the usermust first clear the event by using a global reset button. After thereset, the operation is considered paused. Hitting the resume buttonwill allow the operation to continue.

A stop operation button may be displayed and pressed during an operationto halt said operation. When pressed, the user will be prompted toconfirm the action.

The operator unit may also be configured to accept user-entered commentsthat relate to a lubrication operation or any events (user-generated orotherwise) that occurred during an operation.

After a valve has been lubricated, the user will be asked if more valvesrequire lubrication. If the user selects yes, the operation continuesand valve selection process begins again. If the user selects no, theoperator unit begins generating an operation report and returns to adefault display screen.

An override button may also be displayed and pressed to allow a user toalter the solenoid valve's energized state. If the solenoid valve isde-energized, pressing the override button will cause it to becomeenergized and vice versa. This button will likely be used to prefill aline with lubricant prior to the commencement of a lubricationoperation.

In the event that the remote controller unit is disconnected from theoperator unit or is otherwise unpowered, the operator unit may beconfigured to enter a simulation mode. A communication status indicatormay be displayed on the operator unit display to signal whether or notactive communication with the remote controller unit is occurring.

During simulation mode, the user may interact with the operator unit asdescribed above to run a simulated lubrication operation. During suchoperations, lubricant flow is simulated a predetermined rates (forexample, 0.25 lbs./s for 6A valves, 0.25 oz./s for 6C and 6D valves).Once the simulated calculated lubricant quantity has been reached, thesimulated operation stops normally and indicates “Complete.”

The operator unit may be further programmed to simulate active shutdownevents when in simulation mode. In such cases, the user may select froma list of active shutdown events to observe how the operator unithandles these events. Prior to starting a simulated operation, the usermay select an active shutdown event. The operator unit may altersimulated air pressure, lubricant pressure, and lubricant flow rate tosimulate the relevant active shutdown event.

Regarding the operator unit's calculation of lubricant quantity to beapplied to a valve, as described above, the quantity is derived from thevalve information input into the operator unit by the user. In certainembodiments, once all relevant information has been entered, theoperator unit pulls a preset lubricant quantity value from a data tablestored in memory that corresponds to the user-entered valve data. Thisdata table is populated by valve lubricant quantity values known in theart. The operator unit simply queries the table with the valve data toretrieve the correct lubricant quantity. This value then becomes one ofthe setpoints (specifically related to lubricant flow over time asmeasured by lubricant flow transmitter (FT200)) that will cause thesolenoid valve (SV100) to be closed when said setpoint is reachedthereby signaling completion of target valve lubrication.

As discussed previously, the operator unit may be configured to generateoperation reports and related data in real-time. The operator unit maybe further configured to store these reports and data. For example, thevolume of lubricant used, pump stroke, and volume rate is measured andrelayed to the operator unit to ensure O.E.M. valve requirements aremet. These measurements may be stored in operator unit memory along withparticular well, pipeline, and/or valve details. The operator unit mayalso include a printer 20 that may be used to print selected data. Theoperator unit may also have external media ports 21 that allow transferof collected data to external devices including USB drives.

Other remote observational and control devices may be coupled to thelubrication unit management system via Bluetooth, radio, or other knowntechnologies for wireless communication. Additionally, an applicationmay be run on smartphones and tablets that allows for remote access andcontrol of the lubrication unit management system. The application mayinclude all functionality of the operator unit programming as previouslydescribed. Additionally, in some embodiments, smartphones or tabletsrunning the application may act as an operator unit and be in directcommunication with the remote controller unit.

In some embodiments the lubrication unit management system is rated at15,000 psi and configured to measure the flow of lubrication or sealantswith an NLGI consistency of 4.

In other embodiments, the control software could be integrated into theremote controller unit relying on the remote controller unit only as auser-input terminal and display.

In certain embodiments, the operator unit may include scanning means toread codes or other scannable identifiers (such as RFID and UPC codes)to facilitate data or information entry.

Although the invention has been explained in relation to variousembodiments thereof, it is to be understood that many other possiblemodifications and variations can be made without departing from thespirit and scope of the invention.

1. A lubrication unit management system comprising: an operator unit; a remote lubrication control unit communicably coupled to said operator unit; an air supply unit operationally coupled to said remote lubrication control unit; and a lubricant supply unit operationally coupled to said remote lubrication control unit.
 2. The lubrication unit management system of claim 1 wherein said remote lubrication control unit comprises a programmable logic controller (PLC) and a sensor assembly operationally coupled to said PLC.
 3. The lubrication unit management system of claim 2 wherein said sensor assembly comprises an air pressure transmitter, a lubricant pressure transmitter, a lubricant flow transmitted, and a solenoid valve.
 4. The lubrication unit management system of claim 3 wherein said PLC is configured to actuate said solenoid valve upon receiving an actuation signal from said operator unit.
 5. The lubrication unit management system of claim 4 wherein said operator unit is configured to calculate a target lubricant quantity based on user input valve identification information.
 6. The lubrication unit management system of claim 5 wherein said user input valve identification information comprises valve type.
 7. The lubrication unit management system of claim 3 wherein said PLC is configured to transmit sensor data to said operator unit.
 8. The lubrication unit management system of claim 7 wherein said sensor data comprises air pressure measurements, lubricant pressure measurements, and lubricant flow measurements.
 9. The lubrication unit management system of claim 8 wherein said operator unit comprises a computer having a touchscreen display.
 10. The lubrication unit management system of claim 9 wherein said operator unit is configured to present said sensor data on said touchscreen display.
 11. The lubrication unit management system of claim 4 wherein said solenoid valve is configured to cause air to flow from said air supply unit through said remote lubrication control unit when actuated. 